Tubular liner

ABSTRACT

An apparatus and method according to which a tubular liner is positioned in a preexisting structure such as, for example, a wellbore, a wellbore casing, a pipeline or a structural support, and the tubular liner is anchored to the preexisting structure during radial expansion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. provisional application Ser. No. 60/920,896 filed Mar. 30, 2007, and entitled “Tubular Liner,” which is hereby incorporated herein by reference in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

1. Field of the Invention

The invention relates generally to tubular liners. More particularly, the invention relates to tubular liners positioned in preexisting structures such as, for example, wellbores, wellbore casings, pipelines and structural supports, to facilitate, for example, oil and gas exploration.

2. Background of the Invention

Conventionally, when a wellbore is created, a number of casings or tubular liners are installed in the borehole to prevent collapse of the borehole wall and to prevent undesired outflow of drilling fluid into the formation or inflow of fluid from the formation into the borehole. The borehole is drilled in intervals whereby a tubular liner which is to be installed in a lower borehole interval is lowered through a previously installed tubular liner of an upper borehole interval. As a consequence of this procedure the tubular liner of the lower interval is of smaller diameter than the tubular liner of the upper interval. Thus, the tubular liners are in a nested arrangement with diameters decreasing in downward direction. Cement annuli are provided between the outer surfaces of the liners and the borehole wall to seal the tubular liners from the borehole wall. As a consequence of this nested arrangement a relatively large borehole diameter is required at the upper part of the wellbore. Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings. Moreover, increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.

Conventionally, a wellbore tubular liner cannot be formed during the drilling of a wellbore. Typically, the wellbore is drilled and then a wellbore tubular liner is formed in the newly drilled section of the wellbore. This delays the completion of a well.

Embodiments of described herein are directed to overcoming one or more of the limitations of the existing procedures for forming wellbores and wellheads.

BRIEF SUMMARY OF SOME OF THE PREFERRED EMBODIMENTS

These and other needs in the art are addressed in one embodiment by a method. In an embodiment, the method comprises positioning a radially expandable tubular liner in a preexisting structure. The tubular liner comprising a first portion defining a first outside diameter and a second portion defining a second outside diameter that is greater than the first outside diameter. In addition, the method comprises radially expanding the tubular liner. Further, the method comprises a anchoring the expandable tubular member to the preexisting structure in response to radially expanding the tubular liner.

These and other needs in the art are addressed in another embodiment by a apparatus. In an embodiment, the apparatus comprises a an expandable tubular liner adapted to be positioned in a preexisting structure and radially expanded to line at least a portion of the preexisting structure. The tubular liner comprises a first portion defining a first outside diameter. In addition, the tubular liner comprises a second portion defining a second outside diameter that is greater than the first outside diameter. The second portion anchors the tubular liner to the preexisting structure in response to the radial expansion of the expandable tubular liner.

These and other needs in the art are addressed in another embodiment by a method. In an embodiment, the method comprises positioning a radially expandable tubular liner in a preexisting structure. The tubular liner comprises a first portion defining a first outside diameter and a second portion defining a second outside diameter that is greater than the first outside diameter. In addition, the method comprises radially expanding and plastically deforming the tubular liner. Further, the method comprises anchoring the expandable tubular member to the preexisting structure in response to radially expanding and plastically deforming the tubular liner. Still further, the method comprises sealing the interface between the tubular liner and the preexisting structure in response to radially expanding and plastically deforming the tubular liner. Anchoring the expandable tubular member to the preexisting structure in response to radially expanding and plastically deforming the tubular liner comprises at least one of the following: penetratingly engaging the preexisting structure with the second portion of the tubular liner in response to radially expanding and plastically deforming the tubular liner, compressing the second portion between the preexisting structure and the tubular liner in response to radially expanding and plastically deforming the tubular liner; and compressing the first portion around at least a portion of the second portion in response to radially expanding and plastically deforming the tubular liner. Moreover, the preexisting structure comprises one or more of the following: a wellbore, a wellbore casing, a pipeline, and a structural support.

Thus, embodiments described herein comprise a combination of features and advantages intended to address various shortcomings associated with certain prior devices. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments, and by referring to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:

FIG. 1 is a fragmentary cross-sectional view of an exemplary embodiment of a tubular liner including an expandable tubular member and a sleeve coupled thereto positioned within a wellbore that traverses a subterranean formation.

FIG. 2 is a fragmentary cross sectional view of the tubular liner of FIG. 1 after positioning an expansion device within the expandable tubular member.

FIG. 3 is a fragmentary cross sectional view of the tubular liner of FIG. 2 after operating the expansion device within the expandable tubular member to radially expand and plastically deform at least a portion of the expandable tubular member.

FIG. 4 is a fragmentary cross sectional view of the tubular liner of FIG. 3 after further operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member so that the sleeve penetratingly engages the wall of the wellbore.

FIG. 5 is a fragmentary cross sectional view, not necessarily to scale, of the tubular liner of FIG. 1 positioned within a wellbore that traverses a subterranean formation.

FIG. 6 is a fragmentary cross sectional view of the tubular liner of FIG. 5 after positioning an expansion device within the expandable tubular member.

FIG. 7 is a fragmentary cross sectional view of the tubular liner of FIG. 6 after operating the expansion device within the expandable tubular member to radially expand and plastically deform at least a portion of the expandable tubular member.

FIG. 8A is a fragmentary cross sectional view of the tubular liner of FIG. 7 after further operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member so that the sleeve is compressed between the expandable tubular member and the wall of the wellbore.

FIG. 8B is a fragmentary cross sectional view of the tubular liner of FIG. 7 after further operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member so that the expandable tubular member is compressed around at least a portion of the sleeve.

FIG. 9 is a perspective view, not necessarily to scale, of a tubular liner according to another exemplary embodiment.

FIG. 10 is a sectional view of the tubular liner of FIG. 9.

FIG. 11 is an enlarged portion of the view depicted in FIG. 10.

FIG. 12 is a perspective view, not necessarily to scale, of a tubular liner according to yet another exemplary embodiment.

FIG. 13 is a sectional view of the tubular liner of FIG. 12.

FIG. 14 is an enlarged portion of the view depicted in FIG. 13.

FIG. 15 is a perspective view, not necessarily to scale, of a tubular liner according to yet another exemplary embodiment.

FIG. 16 is a sectional view of the tubular liner of FIG. 15.

FIG. 17 is an enlarged portion of the view depicted in FIG. 16.

DETAILED DESCRIPTION OF SOME OF THE PREFERRED EMBODIMENTS

The following discussion is directed to various embodiments of the invention. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. In addition, one skilled in the art will understand that the following description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to intimate that the scope of the disclosure, including the claims, is limited to that embodiment.

Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices and connections.

In an exemplary embodiment, as illustrated in FIG. 1, a tubular liner is generally referred to by the reference numeral 10 and includes an expandable tubular member 12 and a sleeve 14 coupled thereto so that the expandable tubular member 12 extends through the sleeve 14. The sleeve 14 defines an outside diameter that is greater than the outside diameter defined by the expandable tubular member 12.

During operation, in an exemplary embodiment and as illustrated in FIG. 1, the tubular liner 10 is positioned within a preexisting structure such as, for example, a wellbore 16 that traverses a subterranean formation 18.

In an exemplary embodiment, as illustrated in FIG. 2, an expansion device 20 is then positioned within the expandable tubular member 12. In several exemplary embodiments, the expansion device 20 may be positioned within the expandable tubular member 12 before, during, or after the placement of the expandable tubular member 12 within the wellbore 16.

In an exemplary embodiment, as illustrated in FIG. 3, the expansion device 20 is then operated to radially expand and plastically deform at least a portion of the expandable tubular member 12 of the tubular liner 10.

In an exemplary embodiment, as illustrated in FIG. 4, the expansion device 20 is then further operated to radially expand the remaining portion of the expandable tubular member 12. In response to the radial expansion of the expandable tubular member 12, the sleeve 14 also radially expands and penetratingly engages the wall of the wellbore 16. As a result of the penetration of the sleeve 14 into the wall of the wellbore 16, the tubular liner 10 is anchored to the wellbore 16, thereby generally preventing relative movement therebetween.

In an exemplary embodiment, as illustrated in FIG. 4, in addition to anchoring the tubular liner 10 to the wellbore 16 in response to the radial expansion of the expandable tubular member 12, the sleeve 14 sealingly engages the interface between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 16, thereby fluidicly isolating the portion of the wellbore 16 below the sleeve 14 from the portion of the wellbore 16 above the sleeve 14, and vice versa, in response to the radial expansion of the expandable tubular member 12.

In several exemplary embodiments, as a result of the anchoring of the tubular liner 10 to the wellbore 16, embodiments described herein offer the potential to reduce the risk of the tubular liner 10 being pulled upward or downward, in response to the operation and axial movement of the expansion device 20 during the radial expansion of the portion of the expandable tubular member 12 above or below the sleeve 14 and/or one or more other expandable tubular members coupled to the expandable tubular member 12 above or below the sleeve 14.

In several exemplary embodiments, the ability of the tubular liner 10 to be anchored to a wellbore in response to the radial expansion of the expandable tubular member 12 facilitates, for example, the formation of wellbore casings in, for example, soft formations.

In several exemplary embodiments, as a result of the anchoring of the tubular liner 10 to the wellbore 16 and the sealing of the interface between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 16 in response to the radial expansion of the expandable tubular member 12, there is no need, or at least there is less of a need, to inject a hardenable fluidic material such as, for example, cement, into the annular region defined between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 16 before, during or after the radial expansion of the expandable tubular member 12.

In several exemplary embodiments, before, during or after the operation of the expansion device 20, a hardenable fluidic material such as, for example, cement, is injected into the annular region defined between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 16. As a result, an annular body of the hardenable fluidic sealing material is formed within the annular region defined between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 16. Before, during or after the curing of the annular body of the hardenable fluidic sealing material, the expansion device 20 may be operated to radially expand and plastically deform the expandable tubular member 12.

During operation, in an exemplary embodiment and as illustrated in FIG. 5, the tubular liner 10 is positioned within a preexisting structure such as, for example, a wellbore 22 that traverses a subterranean formation 24.

In an exemplary embodiment, as illustrated in FIG. 6, the expansion device 20 is then positioned within the expandable tubular member 12. In several exemplary embodiments, the expansion device 20 may be positioned within the expandable tubular member 12 before, during, or after the placement of the tubular member 12 within the wellbore 22.

In an exemplary embodiment, as illustrated in FIG. 7, the expansion device 20 is then operated to radially expand and plastically deform at least a portion of the expandable tubular member 12 of the tubular liner 10.

In an exemplary embodiment, as illustrated in FIG. 8A, the expansion device 20 is then further operated to radially expand the remaining portion of the expandable tubular member 12 In response to the radial expansion of the expandable tubular member 12, the sleeve 14 also radially expands until the sleeve 14 engages the wall of the wellbore 22, at which point the sleeve 14 is compressed between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 22. As a result of the compression of the sleeve 14 between the expandable tubular member 12 and the wall of the wellbore 22, and the resulting stresses and/or frictional forces generated therebetween, the tubular liner 10 is anchored to the wellbore 22, thereby generally preventing relative movement therebetween.

Alternatively, in an exemplary embodiment, after operating the expansion device 20 as illustrated in FIG. 7, the expansion device 20 is then further operated to radially expand the remaining portion of the expandable tubular member 12, as illustrated in FIG. 8B. In response to the radial expansion of the expandable tubular member 12, the sleeve 14 also radially expands until the sleeve 14 engages the wall of the wellbore 22, at which point the sleeve 14 is sandwiched between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 22. However, after engaging the wall of the wellbore 22, the sleeve 14 remains substantially intact and the expandable tubular member 12 is instead compressed around the portions of the sleeve 14 not engaging the wall of the wellbore 22, as shown in FIG. 8B. As a result of the sandwiching of the sleeve 14 between the expandable tubular member 12 and the wall of the wellbore 22, the compression of the expandable tubular member 12 around the portions of the sleeve 14 not engaging the wall of the wellbore 12, and the resulting stresses and/or frictional forces generated among the wall of the wellbore 12, the sleeve 14 and the expandable tubular member 12, the tubular liner 10 is anchored to the wellbore 22, thereby generally preventing relative movement therebetween.

In an exemplary embodiment, as illustrated in both FIGS. 8A and 8B, in addition to anchoring the tubular liner 10 to the wellbore 22 in response to the radial expansion of the expandable tubular member 12, the sleeve 14 sealingly engages the interface between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 22, thereby fluidicly isolating the portion of the wellbore 22 below the sleeve 14 from the portion of the wellbore 22 above the sleeve 14, and vice versa, in response to the radial expansion of the expandable tubular member 12.

In several exemplary embodiments, as a result of the anchoring of the tubular liner 10 to the wellbore 22, embodiments described herein offer the potential to reduce the risk of the tubular liner 10 being pulled upward or downward, in response to the operation and axial movement of the expansion device 20 during the radial expansion of the portion of the expandable tubular member 12 above or below the sleeve 14 and/or one or more other expandable tubular members coupled to the expandable tubular member 12 above or below the sleeve 14.

In several exemplary embodiments, the ability of the tubular liner 10 to be anchored to a wellbore in response to the radial expansion of the expandable tubular member 12 facilitates, for example, the formation of wellbore casings in, for example, soft formations.

In several exemplary embodiments, as a result of the anchoring of the tubular liner 10 to the wellbore 22 and the sealing of the interface between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 22 in response to the radial expansion of the expandable tubular member 12, there is no need, or at least there is less of a need, to inject a hardenable fluidic material such as, for example, cement, into the annular region defined between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 22 before, during or after the radial expansion of the expandable tubular member 12.

In several exemplary embodiments, before, during or after the operation of the expansion device 20, a hardenable fluidic material such as, for example, cement, is injected into the annular region defined between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 22. As a result, an annular body of the hardenable fluidic sealing material is formed within the annular region defined between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 22. Before, during or after the curing of the annular body of the hardenable fluidic sealing material, the expansion device 20 may be operated to radially expand and plastically deform the expandable tubular member 12.

During operation, in several exemplary embodiments, the sleeve 14 of the tubular liner 10 penetratingly engages the wall of the wellbore 16 and/or 22 as described above with reference to FIGS. 1, 2, 3 and 4, is compressed between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 16 and/or 22 as described above with reference to FIGS. 5, 6, 7 and 8A, and/or is sandwiched between the exterior surface of the expandable tubular member 12 and the wall of the wellbore 16 and/or 22 as described above with reference to FIGS. 5, 6, 7 and 8B, thereby anchoring the tubular liner 10 to the wellbore 16 and/or 22 and sealing the interface between the exterior of the expandable tubular member 12 and the wall of the wellbore 16 and/or 22.

In an exemplary embodiment, the sleeve 14 is composed of one or more metallic materials. In an exemplary embodiment, the sleeve 14 is composed of one or more non-metallic materials. In an exemplary embodiment, the sleeve 14 is composed of a combination of one or more metallic materials and one or more non-metallic materials.

In an exemplary embodiment, the sleeve 14 is composed of one or more elastomeric materials. In an exemplary embodiment, the sleeve 14 is composed of a Viton® elastomer, a nitrile elastomer, a swellable elastomer, a non-swellable elastomer, and/or any combination thereof.

In an exemplary embodiment, the sleeve 14 is composed of one or more composite materials. In an exemplary embodiment, the sleeve 14 is composed of one or more composite materials that are sprayed onto the exterior surface of the expandable tubular member 12. In an exemplary embodiment, the sleeve 14 is composed of a material that is impregnated with carbide, wire filament and/or any combination thereof. In several exemplary embodiments, the sleeve 14 is composed of a material such as polyetheretherketone/PEEK or polytetrafluoroethylene/PTFE (Teflon®).

In several exemplary embodiments, the sleeve 14 is composed of one or more combinations of any of the above-identified types of materials.

In an exemplary embodiment, the sleeve 14 is integral with the expandable tubular member 12.

In several exemplary embodiments, the tubular liner 10 further includes one or more standoffs coupled to the exterior surface of the expandable tubular member 12. In several exemplary embodiments, the standoffs are composed of one or more resilient materials.

In an exemplary embodiment, the sleeve 14 includes a plurality of circumferentially-spaced fins that extend radially outward away from the exterior surface of the expandable tubular member 12. In an exemplary embodiment, the sleeve 14 includes one or more spikes and/or other types of protrusions that extend radially outward away from the exterior surface of the expandable tubular member 12.

In several exemplary embodiments, in addition to the sleeve 14, the tubular liner 10 includes one or more other sleeves, which are substantially similar to the sleeve 14 and are coupled to the expandable tubular member 12.

In several exemplary embodiments, in addition to the expandable tubular member 12, the tubular liner 10 includes one or more other expandable tubular members, which are substantially similar to the expandable tubular member 12 and are coupled together to form a tubular string, of which the expandable tubular member 12 is a part; in several exemplary embodiments, one or more sleeves 14 that are substantially similar to the sleeve 14 may be coupled to each of the expandable tubular members in the tubular string. In several exemplary embodiments, instead of, or in addition to being coupled to the expandable tubular member 12 at an axial position between the ends of the expandable tubular member 12, the sleeve 14 is coupled at a coupling between the expandable tubular member 12 and another expandable tubular member. In several exemplary embodiments, the sleeve 14 also functions as, or is a part of, a connection sleeve that couples the expandable tubular member 12 to another expandable tubular member.

In several exemplary embodiments, during the operation of the tubular liner 10, one or more discrete portions of the expandable tubular member 12, and thus one or more discrete portions of the tubular liner 10, may be radially expanded and plastically deformed.

In several exemplary embodiments, instead of, or in addition to the wellbore 16 and/or 22, the tubular liner 10 may be coupled to one or more other types of preexisting structures such as, for example, one or more wellbore casings, one or more pipelines, one or more structural supports, and/or any combination thereof.

In an exemplary embodiment, the expansion device 20 includes a vibration mechanism. In an exemplary embodiment, the expansion device 20 includes a vibration mechanism that travels upwards (bottom-up), as viewed in any of FIGS. 1-8. In an exemplary embodiment, the expansion device 20 includes a vibration mechanism that travels downwards (top-down), as viewed in any of FIGS. 1-8. In an exemplary embodiment, the expansion device 20 employs mechanical force to effect its displacement relative to the expandable tubular member 12. In an exemplary embodiment, the expansion device 20 includes a fluid-powered expansion device. In an exemplary embodiment, the expansion device 20 employs hydraulic pressure to effect its displacement relative to the expandable tubular member 12. In an exemplary embodiment, to effect the displacement of the expansion device 20 relative to the expandable tubular member 12, the expansion device 20 employs mechanical force, hydraulic pressure and/or any combination thereof.

In several exemplary embodiments, the radial expansion and plastic deformation of the expandable tubular member 12 using the expansion device 20 is provided using one or more of the disclosures in whole or in part of one or more of the following: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claims priority from provisional application 60/121,702, filed on Feb. 25, 1999, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claims priority from provisional application 60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul. 1, 2002, which claims priority from provisional application 60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent application Ser. 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In an exemplary embodiment, as illustrated in FIGS. 9, 10 and 11, a tubular liner is generally referred to by the reference numeral 26 and includes an expandable tubular member 28 defining an internal passage 28 a, an outside diameter 28 b and an inside diameter 28 c, and including an external threaded connection 28 d at one end and an internal threaded connection 28 e at the other end. In an exemplary embodiment, the outside diameter 28 b is about 6.010 inches and the inside diameter 28 c is about 5.390 inches. In an exemplary embodiment, the external threaded connection 28 d is a pin connection and the internal threaded connection 28 e is a box connection.

Sleeves 30 a, 30 b, and 30 c are coupled to the expandable tubular member 28 so that the expandable tubular member 28 extends through the sleeves 30 a, 30 b and 30 c. The sleeves 30 a, 30 b, and 30 c include opposing tapered end portions, 30 aa and 30 ab, 30 ba and 30 bb, and 30 ca and 30 cb, respectively, and the sleeves 30 a, 30 b, and 30 c are axially spaced from one another along the axial or longitudinal length of the expandable tubular member 28. In an exemplary embodiment, the axial gap between the sleeves 30 a and 30 b is about 2.0 inches, and the axial gap between the sleeves 30 b and 30 c is also about 2.0 inches. Each of the sleeves 30 a, 30 b, and 30 c defines an outside diameter 32 that is greater than the outside diameter 28 b of the expandable tubular member 28. In an exemplary embodiment, the outside diameter 32 is about 6.337 inches. Each of the sleeves 30 a, 30 b and 30 c defines a wall thickness 34. In an exemplary embodiment, the wall thickness 34 is about 0.160 inches before any radial expansion of any of the sleeves 30 a, 30 b and 30 c. Each of the sleeves 30 a, 30 b, and 30 c defines an axial length 36. In an exemplary embodiment, the axial length 36 is about 6.0 inches.

In an exemplary embodiment, the tubular liner 26 operates in a manner substantially similar to the manner in which the tubular liner 10 operates, as described above with reference to FIGS. 1, 2, 3 and 4, with the sleeves 30 a, 30 b, and 30 c penetratingly engaging the wall of a wellbore in response to the radial expansion of the expandable tubular member 28, thereby anchoring the tubular liner 26 to the wellbore and sealing the interface between the exterior surface of the expandable tubular member 28 and the wall of the wellbore.

In an exemplary embodiment, the tubular liner 26 operates in a manner substantially similar to the manner in which the tubular liner 10 operates, as described above with reference to FIGS. 5, 6, 7, 8A and 8B, with the sleeves 30 a, 30 b, and 30 c being compressed between the expandable tubular member 28 and the wall of a wellbore in response to the radial expansion of the expandable tubular member 28, thereby anchoring the tubular liner 26 to the wellbore and sealing the interface between the exterior surface of the expandable tubular member 28 and the wall of the wellbore.

In an exemplary embodiment, the tubular liner 26 operates in a manner substantially similar to the manner in which the tubular liner 10 operates as described above with reference to FIGS. 1, 2, 3 and 4, with the sleeves 30 a, 30 b, and 30 c penetratingly engaging the wall of a wellbore in response to the radial expansion of the expandable tubular member 28, and also in a manner substantially similar to the manner in which the tubular liner 10 operates, as described above with reference to FIGS. 5, 6, 7, 8A and 8B, with the sleeves 30 a, 30 b and 30 c also being compressed between the expandable tubular member 28 and the wall of the wellbore in response to the radial expansion of the expandable tubular member 28.

In an exemplary embodiment, as illustrated in FIGS. 12, 13 and 14, a tubular liner is generally referred to by the reference numeral 38 and includes an expandable tubular member 40 defining an internal passage 40 a, an outside diameter 40 b and an inside diameter 40 c, and including an external threaded connection 40 d at one end and an internal threaded connection 40 e at the other end. In an exemplary embodiment, the outside diameter 40 b is about 6.010 inches and the inside diameter 40 c is about 5.390 inches. In an exemplary embodiment, the external threaded connection 40 d is a pin connection and the internal threaded connection 40 e is a box connection.

Sleeves 42 a and 42 b are coupled to the expandable tubular member 40 so that the expandable tubular member 40 extends through the sleeves 42 a and 42 b. The sleeves 42 a and 42 b include opposing tapered end portions, 42 aa and 42 ab, and 42 ba and 42 bb, respectively, and the sleeves 42 a and 42 b are axially spaced from one another along the axial or longitudinal length of the expandable tubular member 40. In an exemplary embodiment, the axial gap between the sleeves 42 a and 42 b is about 2.0 inches. Each of the sleeves 42 a and 42 b defines an outside diameter 44 that is greater than the outside diameter 40 b of the expandable tubular member 28. In an exemplary embodiment, the outside diameter 44 is about 6.337 inches. Each of the sleeves 42 a and 42 b defines a wall thickness 46. In an exemplary embodiment, the wall thickness 46 is about 0.160 inches before any radial expansion of any of the sleeves 42 a and 42 b. Each of the sleeves 42 a and 42 b defines an axial length 48. In an exemplary embodiment, the axial length 48 is about 12.0 inches.

In an exemplary embodiment, the tubular liner 38 operates in a manner substantially similar to the manner in which the tubular liner 10 operates, as described above with reference to FIGS. 1, 2, 3 and 4, with the sleeves 42 a and 42 b penetratingly engaging the wall of a wellbore in response to the radial expansion of the expandable tubular member 40, thereby anchoring the tubular liner 38 to the wellbore and sealing the interface between the exterior surface of the expandable tubular member 40 and the wall of the wellbore.

In an exemplary embodiment, the tubular liner 38 operates in a manner substantially similar to the manner in which the tubular liner 10 operates, as described above with reference to FIGS. 5, 6, 7, 8A and 8B, with the sleeves 42 a and 42 b being compressed between the expandable tubular member 40 and the wall of a wellbore in response to the radial expansion of the expandable tubular member 40, thereby anchoring the tubular liner 38 to the wellbore and sealing the interface between the exterior surface of the expandable tubular member 40 and the wall of the wellbore.

In an exemplary embodiment, the tubular liner 38 operates in a manner substantially similar to the manner in which the tubular liner 10 operates as described above with reference to FIGS. 1, 2, 3 and 4, with the sleeves 42 a and 42 b penetratingly engaging the wall of a wellbore in response to the radial expansion of the expandable tubular member 40, and also in a manner substantially similar to the manner in which the tubular liner 10 operates, as described above with reference to FIGS. 5, 6, 7, 8A and 8B, with the sleeves 42 a and 42 b also being compressed between the expandable tubular member 40 and the wall of the wellbore in response to the radial expansion of the expandable tubular member 28.

In an exemplary embodiment, as illustrated in FIGS. 15, 16 and 17, a tubular liner is generally referred to by the reference numeral 50 and includes an expandable tubular member 52 defining an internal passage 52 a and including an external threaded connection 52 b at one end, an internal threaded connection 52 c at the other end, tubular portions 52 d, 52 e, 52 f, and 52 g, and enlarged-diameter tubular portions 52 h, 52 i and 52 j. The portion 52 h is located between the portions 52 d and 52 e, the portion 52 i is located between the portions 52 e and 52 f, and the portion 52 j is located between the portions 52 f and 52 g. Each of the portions 52 d, 52 e, 52 f, and 52 g defines an outside diameter 52 k. Each of the portions 52 h, 52 i and 52 j defines an outside diameter 52 l that is greater than the outside diameter 52 k. Each of the portions 52 d, 52 e, 52 f, 52 g, 52 h, 52 i, and 52 j are integral with each other, defining an inside diameter 52 m.

In an exemplary embodiment, each of the portions 52 h, 52 i and 52 j is a machined pad. In an exemplary embodiment, each of the portions 52 d, 52 e, 52 f and 52 g is an external annular recess.

In an exemplary embodiment, the outside diameter 52 k is about 6.00 inches and the outside diameter 52 l is about 6.30 inches. In an exemplary embodiment, the axial or longitudinal length of each of the portions 52 h, 52 i, and 52 j is about 4.0 inches. In an exemplary embodiment, the axial or longitudinal length of each of the portions 52 e and 52 f is about 14.0 inches. In an exemplary embodiment, the external threaded connection 52 b is a pin connection and the internal threaded connection 52 c is a box connection.

In an exemplary embodiment, the tubular liner 50 operates in a manner substantially similar to the manner in which the tubular liner 10 operates, as described above with reference to FIGS. 1, 2, 3 and 4, with the enlarged-diameter portions 52 h, 52 i and 52 j penetratingly engaging the wall of a wellbore in response to the radial expansion of the expandable tubular member 52, thereby anchoring the tubular liner 50 to the wellbore and sealing the interface between the expandable tubular member 52 and the wall of the wellbore.

In an exemplary embodiment, the tubular liner 50 operates in a manner substantially similar to the manner in which the tubular liner 10 operates, as described above with reference to FIGS. 5, 6, 7, 8A and 8B, with the enlarged-diameter portions 52 h, 52 i and 52 j being compressed between the expandable tubular member 52 and the wall of a wellbore in response to the radial expansion of the expandable tubular member 52, thereby anchoring the tubular liner 50 to the wellbore and sealing the interface between the expandable tubular member 52 and the wall of the wellbore.

In an exemplary embodiment, the tubular liner 50 operates in a manner substantially similar to the manner in which the tubular liner 10 operates as described above with reference to FIGS. 1, 2, 3 and 4, with the enlarged-diameter portions 52 h, 52 i and 52 j penetratingly engaging the wall of a wellbore in response to the radial expansion of the expandable tubular member 52, and also in a manner substantially similar to the manner in which the tubular liner 10 operates, as described above with reference to FIGS. 5, 6, 7, 8A and 8B, with the enlarged-diameter portions 52 h, 52 i and 52 j also being compressed between the expandable tubular member 52 and the wall of the wellbore in response to the radial expansion of the expandable tubular member 52.

In an exemplary experimental model, a set of calculation results are provided in Table 1 below. These calculation results are at least partially based on a tubular liner that is similar to the embodiments of tubular liners 26, 38, 50 described above. These calculation results indicate that the embodiments described herein offer the potential to be anchored to at least a wellbore and/or a wellbore casing in response to the radial expansion of the tubular liner 26, 38 and/or 50. These calculation results, and/or the conclusions derived therefrom, are unexpected results.

TABLE 1 External Base Casing Nominal OD 7.625 in. Weight 39.00 lb/ft Nominal ID 6.625 in. API Drift ID 6.500 in. Connection Type VAM ACE Connection ID 6.625 in. Other ID Restriction N/A Launcher Launcher OD 6.250 in. Anchor Hanger Set in Base Casing-Elastomer Thickness 0.230 in. Set in Base Casing-OD 6.460 in. Set in Open Hole-Machined Pad Thickness 0.150 in. Set in Open Hole-OD 6.300 in. Connection Sleeves Set in Base Casing-Thickness 0.100 in. Set in Base Casing-Expanded OD 6.493 in. Set in Open Hole-Thickness 0.100 in. Set in Open Hole-Expanded OD 6.493 in. Pre-Expansion Connection specifications Tension Load Rating⁽¹⁾ 254,800 lb Compressive Load Rating⁽²⁾ 203,800 lb Minimum Parting Load⁽³⁾ 302,500 lb Pure Bend Load^((2,5)) 28.5°/100 ft SET Liner Pre-Expansion Grade EX-80 Nominal Yield Strength 80,000 psi Minimum Ultimate Strength 95,000 psi Nominal OD 6.000 in. Nominal ID 5.390 in. API Drift ID 5.265 in. Nominal Wall Thickness 0.305 in. Weight 18.60 lb/ft Internal Yield 7,120 psi SET Liner Post-Expansion Nominal OD 6.297 in. Nominal ID 5.700 in. Drift ID 5.641 in. Nominal Wall Thickness 0.299 in. Nominal Weight 19.14 lb/ft Internal Yield⁽⁴⁾ 6,640 psi Collapse⁽⁴⁾ 4,180 psi Expansion Ratio 5.8% Post-Expansion Connection Specifications Tension Load Rating⁽¹⁾ 262,400 lb Compression Load Rating⁽²⁾ 170,600 lb Minimum Parting Load⁽³⁾ 311,600 lb Pure Bend Load^((2,5)) 17.1°/100 ft

Any spatial references such as, for example, “upper,” “lower,” “above,” “below,” “between,” “vertical,” “horizontal,” “angular,” “upwards,” “downwards,” “side-to-side,” “left-to-right,” “right-to-left,” “top-to-bottom,” “bottom-to-top,” “top,” “bottom,” “bottom-up,” “top-down,”etc., are for the purpose of illustration only and do not limit the specific orientation or location of the structure described above.

In several exemplary embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Moreover, one or more of the above-described embodiments and/or variations may be combined in whole or in part with any one or more of the other above-described embodiments and/or variations.

While preferred embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the system and apparatus are possible and are within the scope of the invention. For example, the relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. 

1. A method comprising: positioning a radially expandable tubular liner in a preexisting structure, the tubular liner comprising a first portion defining a first outside diameter and a second portion defining a second outside diameter that is greater than the first outside diameter; radially expanding the tubular liner; and anchoring the expandable tubular member to the preexisting structure in response to radially expanding the tubular liner.
 2. The method of claim 1 further comprising: sealing the interface between the tubular liner and the preexisting structure in response to radially expanding the tubular liner.
 3. The method of claim 1 wherein anchoring the expandable tubular member to the preexisting structure in response to radially expanding the tubular liner comprises: penetratingly engaging the preexisting structure with the second portion of the tubular liner in response to radially expanding the tubular liner.
 4. The method of claim 3 wherein the preexisting structure comprises a wellbore formed in a subterranean formation, the wellbore comprising a wall; and wherein penetratingly engaging the preexisting structure with the second portion of the tubular liner in response to radially expanding the tubular liner comprises: penetratingly engaging the wall of the wellbore with the second portion of the tubular liner in response to radially expanding the tubular liner.
 5. The method of claim 1 wherein anchoring the expandable tubular member to the preexisting structure in response to radially expanding the tubular liner comprises: compressing the second portion between the preexisting structure and the tubular liner in response to radially expanding the tubular liner.
 6. The method of claim 5 wherein the preexisting structure comprises a wellbore formed in a subterranean formation, the wellbore comprising a wall; and wherein compressing the second portion between the preexisting structure and the tubular liner in response to radially expanding the tubular liner comprises: compressing the second portion between the wall of the wellbore and the tubular liner in response to radially expanding the tubular liner.
 7. The method of claim 1 wherein anchoring the expandable tubular member to the preexisting structure in response to radially expanding the tubular liner comprises: penetratingly engaging the preexisting structure with the second portion of the tubular liner in response to radially expanding the tubular liner; and compressing the second portion between the preexisting structure and the tubular liner in response to radially expanding the tubular liner.
 8. The method of claim 1 wherein the first and second portions of the tubular liner are integral.
 9. The method of claim 8 wherein the first portion comprises an external annular recess.
 10. The method of claim 8 wherein the second portion comprises a machined pad.
 11. The method of claim 1 wherein the first portion comprises an expandable tubular member and the second portion comprises at least one sleeve, the at least one sleeve coupled to the expandable tubular member so that the expandable tubular member extends through the at least one sleeve.
 12. The method of claim 11 wherein the at least one sleeve is composed of an elastomeric material.
 13. The method of claim 11 wherein the at least one sleeve is composed of one or more of the following: a metallic material; a non-metallic material; a composite material; polyetheretherketone; polytetrafluoroethylene; and a material impregnated with one or more of the following: carbide, and wire filament.
 14. An apparatus comprising: an expandable tubular liner adapted to be positioned in a preexisting structure and radially expanded to line at least a portion of the preexisting structure, the tubular liner comprising: a first portion defining a first outside diameter; and a second portion defining a second outside diameter that is greater than the first outside diameter; wherein the second portion anchors the tubular liner to the preexisting structure in response to the radial expansion of the expandable tubular liner.
 15. The apparatus of claim 14 wherein the first portion comprises at least one expandable tubular member and the second portion comprises at least one sleeve coupled to the expandable tubular member so that the expandable tubular member extends through the at least one sleeve.
 16. The apparatus of claim 15 wherein the at least one sleeve is composed of an elastomeric material.
 17. The apparatus of claim 15 wherein the at least one sleeve is composed of one or more of the following: a metallic material; a non-metallic material; a composite material; polyetheretherketone; polytetrafluoroethylene; and a material impregnated with one or more of the following: carbide, and wire filament.
 18. The apparatus of claim 14 wherein the first and second portions of the tubular liner are integral.
 19. The apparatus of claim 18 wherein the first portion comprises an external annular recess.
 20. The apparatus of claim 18 wherein the second portion comprises a machined pad.
 21. The apparatus of claim 14 wherein the second portion is adapted to penetratingly engage the preexisting structure in response to the radial expansion of the tubular liner to thereby anchor the tubular liner to the preexisting structure.
 22. The apparatus of claim 14 wherein the second portion is adapted to be compressed between the preexisting structure and the tubular liner in response to the radial expansion of the tubular liner to thereby anchor the tubular liner to the preexisting structure.
 23. The apparatus of claim 14 wherein the second portion is adapted to penetratingly engage the preexisting structure in response to the radial expansion of the tubular liner; and wherein the second portion is adapted to be compressed between the preexisting structure and the tubular liner in response to the radial expansion of the tubular liner.
 24. The apparatus of claim 14 wherein the second portion seals the interface between the tubular liner and the preexisting structure in response to the radial expansion of the expandable tubular liner.
 25. A method comprising: positioning a radially expandable tubular liner in a preexisting structure, the tubular liner comprising a first portion defining a first outside diameter and a second portion defining a second outside diameter that is greater than the first outside diameter; radially expanding and plastically deforming the tubular liner; anchoring the expandable tubular member to the preexisting structure in response to radially expanding and plastically deforming the tubular liner; and sealing the interface between the tubular liner and the preexisting structure in response to radially expanding and plastically deforming the tubular liner; wherein anchoring the expandable tubular member to the preexisting structure in response to radially expanding and plastically deforming the tubular liner comprises at least one of the following: penetratingly engaging the preexisting structure with the second portion of the tubular liner in response to radially expanding and plastically deforming the tubular liner; compressing the second portion between the preexisting structure and the tubular liner in response to radially expanding and plastically deforming the tubular liner; and compressing the first portion around at least a portion of the second portion in response to radially expanding and plastically deforming the tubular liner; and wherein the preexisting structure comprises one or more of the following: a wellbore; a wellbore casing; a pipeline; and a structural support. 